Method for forming fire combustion modified batt

ABSTRACT

The present invention relates to a method for forming a fire combustion modified batt. The method comprises the step of forming a blend of nonwoven and oxidized polyacrylonitrile fibers into a web. The oxidized polyacrylonitrile fibers are fire resistant and when blended with nonwoven fibers are relatively easily processed into a batt. A second blend of nonwoven fibers can be formed into a web and layered with the oxidized polyacrylonitrile fiber web to form the batt. The fibers are bonded together with heat, resin or other bonding material and are compressed and cooled. The fire combustion modified batt is useful as fire barriers and fillers in bedding, upholstery and vehicle and aircraft seats, as insulators for apparel, appliances, walls and ducting, as barriers to separate control systems from a heat source, and as components in fire safety gear such as race driver suits and oven and welding mitts.

This application is based on and claims priority to U.S. PatentApplication Ser. No. 60/188,979, entitled Bi-Lofted Fire CombustionModified Batt filed on Mar. 13, 2000.

FIELD OF THE INVENTION

The present invention relates to a method for forming a fire combustionmodified batt. More particularly, the method includes the step offorming a blend of nonwoven fibers and oxidized polyacrylonitrile (PAN)fibers into a web. The oxidized PAN fibers are fire resistant and whenblended with nonwoven fibers are relatively easily processed into abatt. A second blend of nonwoven fibers can be formed into a web andlayered with the web of oxidized PAN and nonwoven fibers to form thebatt. The fibers of the batt are bonded together with heat, resin orother suitable bonding means and are compressed and cooled to set thebatt. The fire combustion modified batt is useful as a fire barrierlayer and filling in bedding, upholstery and vehicle and aircraft seats,as insulators for apparel, appliances, walls, vehicle walls and ducting,as barriers to separate control systems from a heat source, and ascomponents in fire safety gear such as race driver suits, oven andwelding mitts, and the like.

BACKGROUND OF THE INVENTION

Fire retardant barriers are desirable for a wide variety ofapplications. Products for household and public occupancies such ashealth care facilities, convalescent care homes, college dormitories,residence halls, hotels, motels and correctional institutions aresometimes governed by regulations which require certain fire resistantcharacteristics, particularly in bedding and upholstery. Fire barriercomponents are also needed in apparel, fire safety gear, vehicle andaircraft seating and walls, as insulators for appliances, walls,ducting, as barriers to separate sensitive controls from a heat sourceand other similar applications where fire safety is a concern. Effectivefire barriers minimize the amount and rate of heat released from thebarrier upon contact with fire. The rate of heat released is anindication of the intensity of the fire generated from the fire barriermaterial as well as how quickly the fire spreads. Slowing the spread offire advantageously increases the amount of response time for a firevictim to safely escape and a fire department to successfully extinguishthe fire.

In the bedding, upholstery and other industries, foams and nonwovenfibers are used in mattresses, sofas, chairs, and seat cushions, backsand arms. Traditionally, urethane foam has been combined with othertypes of cushioning materials such as cotton batting, latex rubber, andvarious nonwoven fibers in order to impart desirable comfort, loft anddurability characteristics to a finished product. However, urethane foamis extremely flammable and must be chemically treated or coated toimpart fire resistant properties to the foam. Alternatively, neoprenefoam is used in bedding and upholstery products as it is relatively fireresistant. Both neoprene foam and urethane foam which have been treatedfor fire resistancy are relatively expensive.

Synthetic and natural nonwoven fibers also have demonstrated usefulnessin the construction of mattresses and upholstery. Such fibers areinherently lightweight and therefore easy to ship, store and manipulateduring processing. When subjected to open flame, many synthetic fibers,particularly polymer fibers and specifically dry polyester fibers, tendto melt and drip rather than burn. In addition, polymer fibers can becoated for fire resistance. For example, polymer fibers which have beentreated for fire resistance are identified in the industry under thenames Trevira FR, Kelvar and Nomex and are considered to benon-flammable.

Correctional institutions typically use three types of cushion cores formattresses. The cushion cores include foam, densified synthetic nonwovenfiber which has a density of about 1.5 pounds per cubic foot or greater,and cotton batting. Left untreated, cotton fibers are extremelyflammable and burn rapidly. Cotton can, however, be chemically treated,typically with boric acid, to impart fire resistant properties to thecotton. Correctional institutions with heightened fire safety concernsmay require their mattresses to meet certain fire safety standards. Inthese cases, the cushion cores are comprised of neoprene foam or cottonbatting which has been treated with boric acid. However, cotton isextremely moisture absorbent. Thus, mattresses comprised of cotton aredifficult to maintain in a hygienic condition. Furthermore, cottonmattresses are relatively heavy.

Oxidized polyacrylonitrile (PAN) fibers, while fire resistant, aredifficult to process into batts for use as a barrier layer or filling,particularly in bedding and upholstery applications. The fibers arerelatively low in weight and specific gravity making traditional cardingmethods for forming batts difficult. In addition, oxidized PAN fibersare so-called dead fibers as they have relatively little resilience andloft and are incompressible. In certain applications, in particular forbedding and upholstery, a oxidized PAN fiber batt may be unsuitablewhere comfort and loft are desired. Oxidized PAN fibers are also blackin color and thus may be unsuitable in applications which require alight color beneath a light decorative upholstery or mattress layer.

SUMMARY OF THE INVENTION

Through significant time and effort, it has been found that thedifficulties associated with providing a fire barrier layer could beavoided by the method and batt of the present invention. As will beappreciated by one skilled in the art, the novel method and batt areapplicable to a wide variety of products, including as barrier layersand filling materials in bedding and upholstery, as wraps for andreplacements of cushion and arms in furniture, vehicle and aircraftseats, as insulators for apparel, appliances, walls, vehicle walls,ducts and to separate sensitive controls from a heat source, and ascomponents in fire safety gear such as oven or welding mitts, and thelike.

The method of the present invention comprises the steps of blendingcarrier and binder nonwoven fibers and oxidized polyacrylonitrile (PAN)fibers to form a substantially homogeneous blend of the fibers. Thebinder fibers have a relatively low melting point and the carrier fibershave a relatively high melting point. While the homogeneous mixture canbe any of a number of suitable blends, in one embodiment, the binderfiber can be anywhere in the range of about 5 percent to 50 percent byvolume of the blend. The relative percent volume of oxidized PAN fibersto carrier fibers in the remaining blend volume ranges anywhere from 15percent to 85 percent. In a preferred embodiment, the relatively volumeof oxidized PAN fibers to carrier fibers is about 50 percent to 50percent. Thus, for a blend having 10 percent by volume of binder fibersand a 50 to 50 percent relative volume of oxidized PAN fibers to carrierfibers, the volume of oxidized polyacrylonitrile fibers and carrierfibers in the blend is 45 percent each.

The blended fibers are formed into a batt by using a garnett machine,cross layers, an air layer or any other suitable batt forming apparatus.In a garnett and cross laying process, the blend of fibers are formedinto a web for transporting along a conveyor moving in the machinedirection. Successive web layers are layered in the cross direction ontothe conveyor in an progressive overlapping relationship by moving one ormore reciprocating cross-lappers carrying the web back and forth betweena first side of the conveyor and an opposing second side.

The batt is positioned on an air permeable support and a vacuum isapplied through the air permeable support and batt from a first side ofthe batt to an opposing second side of the batt. The vacuum pressure issufficient to substantially compress the web into a desired thickness orloft and at a desired density. In an alternative embodiment, the batt iscompressed between opposing counter rotating rollers proximate themachine direction and spaced apart a predetermined distance to reducethe thickness and increase the density of the batt. Heat is applied tothe web structure at a temperature sufficient to soften the binderfibers but low enough to avoid melting the carrier fibers. The plasticmemory of the softened binder fibers is released in their compressedconfiguration and the fibers fuse to themselves and to the other webfibers to form a batt having interconnected and fused fibers. The battis cooled in its compressed state to reset the plastic memory of thebinder fibers and form a thermal bonded batt having a density andthickness substantially the same as induced in the batt by the vacuumpressure or compression.

In products which require additional loft, compressibility, resilienceand comfort or a light color beneath decorative upholstery, a mattressquilt or other covering for aesthetic purposes, an additional webcomprising nonwoven fibers which are light in color can be formed. Asurface of the nonwoven web is disposed to a surface of the blendedoxidized PAN fiber web to form a batt which is heated, compressed andcooled together. Alternatively, the oxidized PAN web and the nonwovenweb can be heated, compressed and cooled separately and then disposedtogether to form the batt.

The thermal bonded batt has a wide variety of applications in products,depending on its oxidized PAN fiber content and the density of the batt.For example, a batt having a density of less than 1.5 pounds per cubicfoot, defined herein as a hi loft batt, can be used as a fire barrierlayer in mattresses and border panels of mattresses and as a wrap for oran additional layer to cushion seats, backs and arms in furniture,vehicle and aircraft seats. In mattresses and seats having a lightcolored decorative covering, the batt comprising a layer of nonwovenfibers would be positioned with the light colored nonwoven layerproximate the decorative covering to shield it from the dark coloroxidized PAN fibers. The thermally bonded hi-loft batt is also suitableas an insulation lining in apparel and fire safety gear such as, forexample, in fire fighter jackets and oven mitts for welding orindustrial furnace purposes. Further, the hi-loft batt is suitable as afire barrier air filter and as an insulator for appliances such as hotwater tanks and furnaces. Wall insulation and insulation in recreationalvehicle wall cavities are also suitable applications of the hi-loftbatt.

Batts formed from the method of the present invention having a densityof about 1.5 pounds per cubic foot or greater, defined herein asdensified, are suitable as a replacement to cushion backs, seats andarms in furniture, vehicle and aircraft seats. The densified batts arealso suitable in toppers and filling in mattresses, as well asreplacements for mattress cores, such as, for example, the foam or innersprings in mattresses, particularly for use in public occupancies andcorrectional institutions. Additionally, densified batts are suitablefor insulation lining in apparel and safety gear such as race driversuits, and as insulation for walls, furnace wall insulation, and ductinginsulation. Densified batts are particularly suitable for sounddeadening and thermal transfer applications.

In yet another embodiment of the method of the present invention, aresin is used to bond carrier fibers and oxidized PAN fibers to form afire combustion modified batt of the resent invention. In thisembodiment, carrier fibers having a relatively high melting point areblended with oxidized PAN fibers to form a homogeneous mixture. Whilethe homogeneous mixture can be any of a number of suitable blends, theoxidized PAN fibers can be in the range of about 15 percent to 100percent by volume of the batt and, accordingly, the volume of carrierfibers would be from 85 percent to a negligible amount. Thus, for ablend having 85 percent oxidized PAN fibers, the volume of carrierfibers would be about 15 percent. The blended oxidized PAN and carrierfibers can be formed into a web generally according to the garnettmethod for forming the thermally bonded web described herein. An airlaying machine can also be used. Generally, the fibers are introducedinto an air stream which carries the fibers to an air permeable supportsuch as a perforated drum which is rotating. Accumulation of the fibersonto the drum surface results in a web formation. A vacuum is appliedthrough the web from one side of the web to the other and through saidair permeable support sufficient to reduce the thickness and increasethe density of the web throughout the thickness of the web to form abatt. The batt is saturated with a heat curable resin which canadditionally comprise fire resistant properties to enhance the fireresistance of the batt. Heat is applied at a temperature sufficient tocure the resin and fuse the fibers to form a batt having a density andthickness substantially the same as during the heating step. Forproducts requiring additional loft, compressibility, reslience andcomfort or a light color, a web comprising nonwoven fibers can beformed. A surface of the nonwoven web is disposed to a surface of theoxidized PAN fiber web to form a batt which is saturated with a resinand heated to cure the resin. Alternatively, the oxidized PAN fiber weband the nonwoven web can be separately saturated with resin, heat curedand then bonded together by suitable bonding applications. In addition,a relatively thin layer of a nonwoven fiber which is light in color canbe bonded to the resin bonded batt for aesthetic purposes where loft,compression and comfort is not required.

While the resin bonded batt can be hi-loft, preferably it is a densifiedbatt having a density of about 1.5 pounds per cubic foot or greater.Preferably, the batt is relatively thin, having a thickness in the rangeof approximately ⅛ inch to approximately 1 inch. The resin bondeddensified batt can be used as a fire barrier layer in a mattress, suchas for example, directly below the ticking, under the quilt backing,under the quilt panels or borders and above the inner springs. Othersuitable applications include as dust covers in mattresses andfurniture. The densified resin bonded batt is also suitable as a wrapfor cushion seats, backs and arms and for deck padding for furniture andcurtain backing material. Further applications include wraps for hotwater tanks and furnaces and fire and heat shields in building andvehicle walls.

While heat and resin bonding methods are discuss, other methods forbonding the fibers of the web to form the batt of the present inventionare suitable, such as for example, needle punching, hydro-entangling andmechanical bonding, and are within in the scope of the presentinvention.

The invention is more particularly shown and described in theaccompanying drawings and materials included herein.

BRIEF DESCRIPTION OF THE DRAWINGS

For a more complete understanding of the present invention, and forfurther details and advantages thereof, reference is now made to thefollowing Detailed Description of the Drawings taken in conjunction withthe accompanying drawings, in which:

FIG. 1 provides a schematic flow chart of a method according to anembodiment of the present invention.

FIG. 2 provides a schematic top plan view of the processing line forforming a batt according to an embodiment of the method of the presentinvention.

FIG. 3A provides a schematic side view of a thermal bonding apparatusaccording to an embodiment of the method of the present invention.

FIG. 3B provides a schematic side view of another embodiment of athermal bonding apparatus according to the method of the presentinvention.

FIG. 4 provides a perspective top view of an embodiment of a batt formedfrom the method of the present invention.

FIG. 5 provides a perspective top view of another embodiment of a battformed from the method of the present invention.

FIG. 6 provides a schematic flow chart of a method according to anotherembodiment of the present invention.

FIG. 7 provides a perspective top view of further embodiment of a battformed from the method of the present invention.

FIG. 8A is a side cut away view of a traditional mattress.

FIG. 8B is a side cut away view of a mattress comprising embodiments ofbatts formed from the method of the present invention.

FIG. 9 is a side view of a mattress border comprising an embodiment of abatt formed from the method of the present invention.

DETAILED DESCRIPTION OF THE DRAWINGS

The method for forming a fire combustion modified batt of the presentinvention comprises a process for bonding web fibers together to form abatt. The bonding processes discussed herein include a thermal bondingprocess and a resin saturated curing process. However, other methods maybe suitable for bonding web fibers together to form a fire combustionmodified batt and thus are within the scope of the invention. Forexample, needle punching, hydro entangling and mechanical bonds aresuitable.

Turning first to the thermal bonding process which is representativelyand schematically illustrated in FIG. 1, the method comprises the stepof blending nonwoven fibers and oxidized polyacrylonitrile (PAN) fibersto form a first web blend. For purposes of illustrating the process andnot by way of limitation, the oxidized polyacrylonitrile (PAN) fibers ofthe present invention are marketed under the product name Pyron byZoltek Corporation. The oxidized polyacrylonitrile (PAN) fibers areproduced from an acrylic precursor. Specifically, the Pyron oxidized PANfiber is a stabilized form of polyacrylonitrile (PAN) fiber. Thestabilization is an oxidation process that converts thepolyacrylonitrile (PAN) fiber from a thermoplastic state to a thermosetstate.

The discussion herein illustrates generally the method for forming, andthe composition of, oxidized PAN fibers but is not a limitation to thescope of the invention. Other methods and compositions may be suitablefor the present invention as would be understood by one skilled in theart. Generally, several types of acrylic polymers with variations intheir composition have been used for the production of oxidized PANfibers. The exact composition of a particular acrylic precursor varieswidely. Generally, however, the composition contains a minimum of 85%acrylonitrile and a maximum of 15%, but preferably no more than 8%,comonomers such as methyl methacrylate, methyl acrylate, vinyl acetate,vinyl chloride, and other monovinyl compounds.

In addition to acrylic as a precursor for the production of carbonfibers, rayon and pitches are also used. The details of the conversionprocesses used for different precursors are not the same, although theiressential features are similar. Generally, the processes involve astabilizing treatment to prevent melting or fusion of the fiber, acarbonizing treatment to eliminate the non-carbon elements and a hightemperature graphitizing treatment to enhance the mechanical propertiesof the final carbon fiber.

In the case of PAN fibers, stabilization is carried out by controlledheating of the precursor fiber in an oxidizing atmosphere, for example,in air in the temperature range of about 180° C. to 300° C. The heatingrate is usually 1–2° C./minute. However, other temperature ranges andheating rates may be appropriate. Shrinkage can be minimized bystretching the fibers along their axis during the low-temperaturestabilization treatment. Stretching also produces oxidized PAN fiberswith a high degree of preferred orientation along the fiber axis. Thestabilization process produces changes in chemical structure of theacrylic precursor such that the product becomes thermally stable tosubsequent high temperature treatments. During this process, the fiberschange in color to black. The black fibers are carbonized in an inertatmosphere at high temperatures, for example at 1000 to 1500° C. with aslow heating rate to avoid damage to the molecular order of the fiber.The fibers are given a graphitizing treatment at high temperatures forexample, above 2000° C. to 3000° C., to improve the texture of the fiberand to enhance the Young's modulus. The strength and the modulus of thefibers can also be improved by hot stretching.

Generally, the physical characteristics of oxidized PAN fibers are itsblack color, a moisture content of about 4 to 9 percent, an averagefiber diameter of about 11 to 14 microns, a fiber tensile strength ofabout 180 to 300 Mpa, a fiber elongation of about 18 to 28 percent, afiber density of about 1.36 to 1.38 g/cc and a fiber length of about 4to 15 cm. In addition, in the case of Pyron, the oxidized PAN fibers arethermally stable up to 600° F. The physical and chemical properties mayvary depending on the specific manufacturing process.

The nonwoven fibers of the first blend for the present invention includecarrier fibers and binder fibers. The fibers can be natural orsynthetic. For example, thermoplastic polymer fibers such as polyesterare suitable synthetic fibers. Other fibers can be used depending uponthe precise processing limitations imposed and the characteristics ofthe batts which are desired at the end of the process. For purposes ofillustrating the process and combustion modified batt and not by way oflimitation, the carrier fiber is KoSa Type 209, 6 to 15 denier, 2 to 3inches in length, round hollow cross section polyester fiber.Alternatively, the carrier fiber is KoSa Type 295, 6 to 15 denier, ⅕ to4 inches in length, pentalobal cross section polyester fiber. Othernonwoven fibers are suitable as carrier fibers for the present inventionand are within the scope of this invention.

The binder fiber has a relatively low predetermined melting temperatureas compared with the carrier fiber. As used herein, however, the termmelting does not necessarily refer only to the actual transformation ofthe solid polyester binder fibers into liquid form. Rather, it refers toa gradual transformation of the fibers or, in the case of a bicomponentsheath/core fiber, the sheath of the fiber, over a range of temperatureswithin which the polyester becomes sufficiently soft and tacky to clingto other fibers within which it comes in contact, including other binderfibers having its same characteristics and, as described above, adjacentpolyester fibers having a higher melting temperature. It is an inherentcharacteristic of thermoplastic fibers such as polyester that theybecome sticky and tacky when melted, as that term is used herein. Forpurposes of illustrating the process and fire combustion modified battand not by way of limitation, the binder fiber is KoSa Type 254 Celbond®which is a bicomponent fiber with a polyester core and a copolyestersheath. The sheath component melting temperature is approximately 230°F. (110° C.). The binder fiber, alternatively, can be a polyestercopolymer rather than a bicomponent fiber.

While the homogeneous mixture of nonwoven fibers and oxidized PAN fiberscan be any of a number of suitable fiber blends, for purposes ofillustrating the process and first blend, the mixture is comprised ofbinder finders in an amount sufficient for binding the fibers of theblend together upon application of heat at the appropriate temperatureto melt the binder fibers. In one example, the binder fibers are in therange of approximately 5 percent to 50 percent by total volume of theblend. Preferably, the binder finders are present in the range ofapproximately 10 percent to 15 percent for a hi loft batt, and in therange of approximately 15 percent to 40 percent for a densified batt, asthose characteristics are discussed below. The relative percent volumeof oxidized PAN fibers to carrier fibers in the remaining blend volumeranges anywhere from 15 percent to 85 percent. In the preferredembodiment, the relative volume of oxidized PAN fibers to carrier fibersis about 50 percent to 50 percent. Thus, for example, a blend having 10percent by volume of binder fibers and a 50 to 50 percent relativevolume of oxidized PAN fibers to carrier fibers, the volume of oxidizedPAN fibers and carrier fibers in the blend is 45 percent each. Inanother example, the volume of oxidized PAN fibers and carrier fibers inthe blend is 45 percent each. In a further example, the volume ofoxidized PAN fibers and carrier fibers having a 50 to 50 percentrelative volume is 40 percent each in a blend having 20 percent byvolume of binder fibers. In a further example, a blend having 20 percentbinder fibers and a 75 percent to 25 percent relative volume mix ofoxidized PAN fibers to carrier fibers, the volume of oxidized PAN fibersand carrier fibers is 60 percent and 20 percent, respectively. Blendshaving other percentages of binder, carrier and oxidized PAN fibers arealso within the scope of the invention.

Referring back to FIG. 1, the method further comprises an optional stepof blending a homogenous second blend of carrier and binder fibers toform a second web. The fibers can be the same as or similar to those ofthe first web discussed herein, such as, for example, polyester fibers.Other synthetic or natural fibers can be used depending upon the preciseprocessing limitations imposed and the characteristics of the second webwhich are desired at the end of the process. While the homogeneousmixture of carrier and binder fibers can be any of a number of suitablefiber blends, for purposes of illustrating the process and second blend,the mixture is comprised of binder finders in the range of approximately10 percent to 20 percent by volume and carrier fibers in the range ofapproximately 90 to 80 percent by volume. Preferably, the binder findersand carrier fibers are present in the range of approximately 10 percentto 15 percent and approximately 90 to 85 percent by volume,respectively.

Referring to FIG. 2, a schematic top plan view of the general processingline 10 for forming a batt of the present invention is illustrated. Thefollowing example is directed to the formation of a web in general andthus is applicable to forming both the first web comprising oxidized PANfibers and nonwoven fibers and the second web of nonwoven fibers. Asdiscussed above, fibers are blended in a fiber blender 12 and conveyedby conveyor pipes 14 to a web forming machine or, in this example, threemachines 16, 17, 18. A suitable web forming apparatus is a garnettmachine. An air laying machine, known in the trade as a Rando webber, orany other suitable apparatus can also be used to form a web structure.Garnett machines 16, 17, 18 card the blended fibers into a nonwoven webhaving a desired width and deliver the web to cross-lappers 16′, 17′,18′ to cross-lap the web onto a slat conveyor 20 which is moving in themachine direction. Cross-lappers 16′, 17′ 18′ reciprocate back and forthin the cross direction from one side of conveyor 20 to the other side toform the web having multiple thicknesses in a progressive overlappingrelationship. The number of layers which make up the web is determinedby the speed of the conveyor 20 in relation to the speed at whichsuccessive layers of the web are layered on top of each other and thenumber of cross-lappers 16′, 17′, 18′. Thus, the number of single layerswhich make up the web can be increased by slowing the relative speed ofthe conveyor 20 in relation to the speed at which cross layers arelayered, by increasing the number of cross-lappers 16′, 17′ 18′ or both.Conversely, a fewer number of single layers can be achieved byincreasing the relative speed of conveyor 20 to the speed of laying thecross layers, by decreasing the number of cross-lappers 16′, 17′, 18′ orboth. In the present invention, the number of single layers which makeup the first web of oxidized PAN and nonwoven fibers and the second webof nonwoven fibers can be approximately the same or can vary dependingon the desired characteristics of the fire combustion modified batt ofthe present invention. Accordingly, the relative speed of the conveyor20 to the speed at which cross layers are layered and the number ofcross-lappers 16′, 17′, 18′ for forming the first web and the second webmay be different.

Referring back to FIG. 1, the process of the present invention furthercomprises disposing a surface of the first web in a conformingrelationship to a surface of the second web to form the fire combustionmodified batt.

While there are a variety of thermal bonding methods which are suitablefor the present invention, one such method comprises holding the batt byvacuum pressure applied through perforations of first and secondcounter-rotating drums and heating the batt so that the relatively lowmelting temperature binder fibers in the first web and the second websoften or melt to the extent necessary to fuse the low melt binderfibers together and to the oxidized PAN and carrier fibers in the firstand second webs. Alternatively, the batt moves through an oven bysubstantially parallel perforated or mesh wire aprons to melt the lowtemperature binder fibers.

Referring to FIGS. 2 and 3A, a vacuum pressure method generallycomprises using counter-rotating drums 40, 42 having perforations 41,43, respectively, which are positioned in a central portion of a housing30. Housing 30 also comprises an air circulation chamber 32 and afurnace 34 in an upper portion and a lower portion, respectively,thereof. Drum 40 is positioned adjacent an inlet 44 through which thebatt is fed. The batt is delivered from the blending and web formingprocesses described herein by means of an infeed apron 46. A suction fan50 is positioned in communication with the interior of drum 40. Thelower portion of the circumference of drum 40 is shielded by a baffle 51positioned inside drum 40 so that the suction-creating air flow isforced to enter drum 40 through perforations 41 which are proximate theupper portion of drum 40 as it rotates.

Drum 42 is downstream from drum 40 in housing 30. Drums 40, 42 can bemounted for lateral sliding movement relative to one another tofacilitate adjustment for a wide range of batt thicknesses (not shown).Drum 42 includes a suction fan 52 which is positioned in communicationwith the interior of drum 42. The upper portion of the circumference ofdrum 42 is shielded by a baffle 53 positioned inside drum 42 so that thesuction-creating air flow is forced to enter drum 42 throughperforations 43 which are proximate the lower portion of drum 42 as itrotates.

The batt is held in vacuum pressure as it moves from the upper portionof rotating drum 40 to the lower portion of counter rotating drum 42.Furnace 34 heats the air in housing 30 as it flows from perforations 41,43 to the interior of drums 40, 42, respectively, to soften or melt therelatively low melting temperature binder fibers in the first and secondwebs to the extent necessary to fuse the low melt binder fibers togetherand to the oxidized PAN and carrier fibers in the first and second webs.

Referring to FIG. 3B, in an alternative thermal bonding process, thebatt enters housing 30′ by a pair of substantially parallel perforatedor mesh wire aprons 60, 62. Housing 30′ comprises an oven 34′ whichheats the batt to soften or melt the relatively low melting temperaturebinder fibers in the first and second webs to the extent necessary tofuse the low melt binder fibers together and to the oxidized PAN andcarrier fibers in the first and second webs.

Referring back to FIGS. 2, 3A and 3B, the batt is compressed and cooledas it exits from housing 30, 30′ by a pair of substantially parallelfirst and second perforated or wire mesh aprons 70, 72. Aprons 70, 72are mounted for parallel movement relative to each other to facilitateadjustment for a wide range of batt thicknesses (not shown). The battcan be cooled slowly through exposure to ambient temperature air or,alternatively, ambient temperature air can forced through theperforations of one apron, through the batt and through the perforationsof the other apron to cool the batt and set it in its compressed state.The batt is maintained in its compressed form upon cooling since thesolidification of the low melt temperature binder fibers in theircompressed state bonds the fibers together in that state.

Referring to FIGS. 1 and 2, the cooled batt moves into cutting zone 80where its lateral edges are trimmed to a finished width and it is cuttransversely to the desired length of batt.

Referring to FIGS. 4 and 5, an example of batt 100 and batt 200 formedby the thermal bonding method of the present invention is illustrated.Batt 100 is comprised of first web 110 having nonwoven fibers 112 andoxidized PAN fibers 114, and second web 120 having nonwoven fibers 122as discussed previously. Batt 200 is comprised of first web 210 havingnonwoven fibers 212 and oxidized PAN fibers 214. The weight, density andthickness 102, 202 of batt 100, 200, respectively, are determined by,among other factors, the process of compressing the batt is it iscooled. The ratio of batt density to batt thickness 102 generallydictates whether batt 100 is a hi loft batt or a densified batt. Forpurposes herein, a densified batt has approximately a 2 to 1 or greaterratio of weight in ounces per square foot to thickness in inches.Accordingly, a densified batt has a density of approximately 1.5 poundsper cubic foot or more. Batts have less than a 2 to 1 ratio of weight tothickness and less than 1.5 pounds per cubic foot density are definedherein as hi-loft batts. For illustration purposes, batt 100 is ahi-loft batt while batt 200 is densified. Tables I, II and III providesexamples of various weights and corresponding thicknesses of battsprocessed by the thermal bonding method of the present invention.

TABLE I* Weight Thickness (oz/sq.ft.) (inches) ¼–½ ½ ½–¾ ¾ ¾–1 ⅞ 1–1¼ 1¼1¼–1½ 1½ 1½–1¾ 1¾ 1¾–2 2 2–2¼ 2¼ 2¼–2¾ 2¾ 2¾–3 3 3–3½ 3½ 3½–4 4*Suitable blends for the weights and thicknesses in Table I arethermally bonded batts having bicomponent low melt binder fibers in theamount of approximately 10 percent to 20 percent by total volume of theblend. The remaining blend volume comprises a relative percent volume ofoxidized PAN fibers to carrier fibers in the range of approximately 15percent to 85 percent by relative volume.

TABLE II* Weight Thickness (oz/sq.ft.) (inches) ⅜–¾ ¼ ¾–1½ ½ 1⅛–2¼ ¾1⅜–2⅜ ⅞ 1½–3 1 1⅝–3⅜ 1⅛ 1⅞–3¾ 1¼ 2¼–4½ 1½ 2⅝–5¼ 1¾ 3–6 2 3¼–6⅜ 2⅛ 3⅜–6¾2¼ 3¾–7½ 2½ 4⅛–8¼ 2¾ 4½–9 3 *Suitable blends for the weights andthicknesses in Table II are thermally bonded batts having bicomponentlow melt binder fibers in the amount of approximately 10 percent to 20percent by total volume of the blend. The remaining blend volumecomprises a relative percent volume of oxidized PAN fibers to carrierfibers in the range of approximately 15 percent to 85 percent byrelative volume. The batts are compressed to a ratio of weight (ouncesper square foot) to thickness (inches) in the range of about 1.5 to 1ratio up to about 3 to 1 ratio.

TABLE III* Weight Thickness (oz/sq.ft.) (inches) 4–6¼ 3⅛ 4⅛–6½ 3¼ 4⅜–73½ 4⅝–7½ 3¾ 5–8 4 5⅛–8¼ 4⅛ 5¼–8½ 4¼ 5⅝–9 4½ 5⅞–9½ 4¾ 6¼–10 5 6⅜–10¼ 5⅛6½–10½ 5¼ 6⅞–11 5½ 7¼–11½ 5¾ 7½–10½ 6 7⅝–10⅝ 6⅛ 7⅞–11 6¼ 8⅛–11⅜ 6½8½–10⅛ 6¾ 8¾–10½ 7 8⅞–10⅔ 7⅛ 9–10⅞ 7¼ 9⅜–11¼ 7½ 9⅝–11 1/16 7¾ 10–12 8*Suitable blends for the weights and thicknesses in Table III arethermally bonded batts having bicomponent low melt binder fibers in theamount of approximately 10 percent to 20 percent by total volume of theblend. The remaining blend volume comprises a relative percent volume ofoxidized PAN fibers to carrier fibers in the range of approximately 15percent to 85 percent by relative volume. The batts are compressed to aratio of weight (ounces per square foot) to thickness (inches) in therange of about 1.25 to 1 ratio up to about 2 to 1 ratio.

Referring to FIG. 6, the method for forming the fire combustion modifiedbatt comprising resin bonding process is representatively andschematically illustrated. Oxidized PAN fibers and carrier fibers areblended to form a first web. Low melt temperature binder fibers are notrequired as a heat curable binder material is used. The oxidized PANfibers and carrier fibers of the blend for the thermal bonding processare suitable for this application as well. For example, Pyron is asuitable oxidized PAN fiber and thermoplastic fibers such as polyester,and more specifically, KoSa Type 209 or KoSa Type 295 are suitablecarrier fibers. However, other synthetic and natural fibers can be useddepending upon the precise processing limitations imposed and thecharacteristics of the batt which are desired at the end of the process.While the mixture of oxidized PAN fibers and carrier fibers in the firstweb for the resin bonding method can be any of a number of suitablefiber blends, for purposes of illustrating the process, the first blendis comprised of oxidized PAN fibers in the range of approximately 15percent to 100 percent by volume and corresponding carrier fibers in therange of approximately 85 percent to a negligible amount.

Referring back to FIG. 5, the resin bonding method can also optionallycomprise a second blend of carrier nonwoven fibers to form a second web.The nonwoven fibers can be the same as or similar to those blended withthe oxidized PAN fibers discussed above, such as, for example, polyesterthermoplastic polymer fibers. Other synthetic or natural fibers can beused depending upon the precise processing limitations imposed and thecharacteristics of the second web which are desired at the end of theprocess.

The resin bonding method further comprises forming a first web and asecond web, from first and second blends, respectively, using webforming machines such as garnetts, cross-lappers or air layingapparatus. The method also comprises the step of disposing a surface ofthe first web in a conforming relationship to a surface of the secondweb to form the batt. While the second nonwoven web provides a lightercolor to a surface of the batt and may impart additional loft andcomfort, alternatively, a relatively thin layer of a nonwoven facingmaterial may be suitable for reinforcement to the first web of oxidizedPAN and carrier fibers. The web and batt forming steps for the resinbonding method are generally similar to those for the thermal bondingprocess which details are discussed above. An air laying machine canalso be used. Generally, the fibers are introduced into an air streamwhich carries the fibers to an air permeable support such as aperforated drum which is rotating. Accumulation of the fibers onto thedrum surface results in a web formation. A vacuum is applied through theweb from one side of the web to the other and through said air permeablesupport sufficient to reduce the thickness and increase the density ofthe web throughout the thickness of the web to form a batt.

Referring back to the schematic of FIG. 6, heat curable resin is appliedto the batt for bonding the web fibers. While there are a variety ofapplications, generally resin in the form of liquid is sprayed whilefroth resin is extruded onto the batt. Alternatively, the batt is fed ordipped into a bath of resin. Resins suitable for the present inventionare curable by heat and can be any of a variety of compositions.Generally, the resin is comprised of latex or acrylic binders.Additionally, the resin can comprise fire resistant chemicals whichfurther enhance the fire resistance of the finished batt.

In the application of liquid resin, as the batt moves along a conveyorin the machine direction, the resin is sprayed onto the batt from one ormore spray heads which move in a transverse or cross direction tosubstantially coat the batt. Froth resin is extruded onto the batt usinga knife or other means. The batt could also be fed through or dippedinto a resin bath. The applied resin is crushed into the batt forsaturation therethrough by nip rollers which are disposed along thetransverse direction of the conveyor to apply pressure to the surface ofthe batt. Alternatively, the resin is crushed into the batt by vacuumpressure applied through the batt. The batt moves into an oven heated toa temperature which cures the resin. The batt exits the oven and iscooled. The batt is maintained substantially in its oven state uponcooling since the heat cures the resin which bonds the fibers of thebatt together in this state. The batt moves into a cutting zone whereits lateral edges are trimmed to a finished width and it is cuttransversely to the desired length.

Referring to FIG. 7, an example of batt 300 formed by the resinsaturated bonding method of the present invention is illustrated. Batt300 is comprised of first web 310 having carrier fibers 312 and oxidizedPAN fibers 314 and a relatively thin nonwoven layer 320. The weight,density and thickness 302 of batt 300 are determined by, among otherfactors, the heating process which cures the resin and fixes the web inthis state. Batt 300 can be hi loft or densified depending on theprocessing conditions and the desired batt characteristics. As discussedherein, a densified batt has approximately a 2 to 1 or greater ratio ofweight in ounces per square foot to thickness in inches which, in termsof density is approximately 1.5 pounds per cubic foot or more. Forillustration purposes, batt 300 is densified. Table IV provides examplesof various weights and corresponding thicknesses of batts processed bythe resin bonding method of the present invention.

TABLE IV* Weight Thickness (oz/sq.ft.) (inches) ¼–¾ ⅛–¼ ¾–1½ ¼–½ 1½–3½–1 *Suitable blends for the weights and thicknesses in Table IV areresin bonded batts having from 15 percent oxidized PAN fibers up to 100percent and the remaining volume of polymer carrier fibers.

Referring to FIGS. 8A and 8B, side views of a traditional mattress andone which incorporates the thermal and resin bonded batts of the presentinvention are provided. In the construction of a traditional mattress400, upper structure 420 positioned over the coil structure 440 includesa quilt panel 422 comprising a cover or ticking 424, a layer of fiber426 and a quilt backing 428. Ticking 424, fiber layer 426 and quiltbacking 428 are stitched together and from quilt pattern 423. The quiltpanel 422 provides loft, comfort and resilience to the mattress 400.Upper structure 420 of the mattress 400 further comprises a layer offoam filling 430 which imparts durability to the mattress 400 as thefoam is relatively stiff as compared to a fiber layer. An insulator 432separates the foam filling 430 from the coils 440 to minimize the wearof the foam filling 430 which coils 440 may impart. The lower structurepositioned under the coil structure 440 is a mirror image of the upperstructure 440 and thus is not shown.

Referring to FIGS. 4, 5, 7 and 8B, mattress 400′ which incorporates thefire combustion modified batts of the present invention is shown. Quiltpanel 422′ of upper structure 420′ is comprised of ticking 424, a resinbonded densified batt 300 having the light colored nonwoven layer 320proximate the ticking 424, a thermally bonded hi-loft batt of oxidizedPAN and nonwoven fibers 110 and a resin bonded densified batt 310 whichreplaces quilt backing 428. The resin bonded batt 300 provides fireresistant properties to the mattress near its surface where a flame islikely to contact while providing a light color for aesthetic purposes.The thermal bonded hi loft fire combustion modified batt 110 providessufficient loft, comfort and resilience to effectively replace the fiberlayer 426 of the traditional mattress quilt panel 422 while impartingadditional fire resistance to the mattress. Upper structure 420′ ofmattress 400′ further comprises a thermally bonded densified batt 200which replaces foam filling 430 to impart durability to mattress 400′.Insulator 432 is replaced with resin bonded batt 310 to enhance the fireresistant properties of mattress 400. A second thermally bondeddensified batt 200 replaces the coil structure 440.

Referring to FIG. 9, a mattress border 500 constructed of a thermallybonded hi loft batt 100 of the present invention is provided. Border 500further comprises ticking 502, a foam layer 504 and a quilt backing 506.Batt 100 has a layer 120 of carrier and binder fibers 122 which isproximate ticking 502 and layer 110 of oxidized PAN fibers 114 andcarrier and binder fibers 112 which is proximate the foam layer 504.Ticking 502, batt 100, foam layer 504 and quilt backing 506 are stitchedtogether and form quilt pattern 508. The thermal bonded hi loft firecombustion modified batt 100 provides loft, comfort and resilience tothe border while providing fire resistant properties to the border and alight color layer 120 of carrier and binder fibers 122 proximate ticking502 for aesthetic purposes.

The thermal and resin bonded batts formed from the methods of thepresent invention offer substantial advantages as fire barrier layers ina wide variety of products, particularly as mattress componentsdescribed above. Fire tests conducted on three mattresses whichincorporate various batts of the present invention were conducted underthe State of California Technical Bulletin 129 Flammability TestProcedure for Mattresses for Use in Public Building, October 1992. Abrief description of the test is as follows. A mattress is placed on asupport system. Flames from a multi hole burner (fueled by propane atthe rate of 12 l/min) impinge on the side of the mattress for a periodof 180 seconds. Test observations are made. The tests were performed onmattresses comprising the fire combustion modified batts to determine,among other things, the burning behavior of the mattresses by measuringthe response time which the fire barrier layers would provide to a firevictim to safely escape and a fire department to successfully extinguishthe fire.

In a first test, a traditional mattress comprising a quilt panel ofticking, a polyester fiber layer, a urethane foam layer and a quiltbacking, two layers of foam and an insulator proximate the coilstructure was tested under the California Technical Bulletin 129. Thetest ended after 1 minute 27 seconds when unsafe escalating combustionwas noted. In a second test, a thermally bonded hi loft batt replacedthe polyester fiber layer beneath the ticking of a mattress describedunder the first test. The thermally bonded hi loft batt was comprised ofa first layer of approximately 10 to 15 percent by volume of binderpolyester fibers and the remaining volume was a 50 to 50 percent byvolume blend of Pyron oxidized PAN fibers and polyester carrier fibers.The batt further comprised a second layer of approximately 10 to 15percent by volume of binder polyester fibers and the remaining volumewas carrier polyester fibers. The weight of each layer was approximately0.5 ounce per square inch for a total batt weight of about 1 ounce persquare inch. The second test ended after 18 minutes 40 seconds beforeunsafe escalating combustion was noted. Thus, the use of a fire barrierlayer in a mattress as described in the second test effectivelyincreased the time by 17 minutes 13 seconds over the traditionalmattress of the first test. This increase could provide valuable timefor a fire victim to escape or a fire department to extinguish the fire.

In a third test, a densified resin bonded batt replaced the insulatorproximate the coil structure of the traditional mattress of the firsttest. The densified batt was comprised of 50 percent by volume ofoxidized PAN fibers and 50 percent by volume of polyester fibers andweighed about ¾ ounces per square foot. The third test ended after 30minutes 43 seconds before unsafe escalating combustion was noted. Thus,the use of a densified batt formed from the method of the presentinvention substantially increases the time over the traditional mattressof the first test by 29 minutes 16 seconds.

The thermal and resin bonded batts formed from the methods of thepresent invention offer substantial advantages as fire barrier layers inother products as well. For example, a thermally bonded fire combustionmodified batt having a density of less than 1.5 pounds per cubic foot, ahi loft batt, can be used as a wrap for or an additional layer tocushion seats, backs and arms in furniture, vehicle and aircraft seats.In seats having a light colored decorative covering, the batt comprisinga layer of nonwoven fibers would be positioned with the light coloredlayer proximate the decorative covering to essentially hide the darkcolor oxidized PAN fiber. The thermally bonded hi-loft batt is alsosuitable as an insulation lining in apparel and fire safety gear suchas, for example, in fire fighter jackets and oven mitts for welding orindustrial furnace purposes. Further, the hi-loft batt is suitable as afire barrier air filter and as an insulator for appliances such as hotwater tanks and furnaces. Insulation for building walls and recreationalvehicle wall cavities are also suitable applications of the hi-loftbatt.

Thermal bonded batts formed from the method of the present inventionhaving a density of about 1.5 pounds per cubic foot or greater,densified batts, are suitable as a replacement to cushion backs, seatsand arms in furniture, vehicle and aircraft seats. The densified battsare also suitable as replacements for mattress cores, such as, forexample, the foam or inner springs in mattresses, particularly for usein public occupancies and correctional institutions. Additionally,densified thermally bonded batts are suitable for insulation lining inapparel and safety gear such as race driver suits, and as insulation forwalls, furnaces and ducting applications. Densified thermally bondedbatts are particularly suitable for sound deadening and thermal transferapplications.

Resin bonded batts, preferably densified batts which are relativelythin, having a thickness in the range of approximately ⅛ inch toapproximately ½ inch, have applications as dust covers in mattresses andfurniture. Densified resin bonded batts are also suitable as wraps forcushion seats, backs and arms and for deck padding for furniture andcurtain backing material. Further applications include wraps for hotwater tanks and furnaces and fire and heat shields in building andvehicle walls.

While preferred embodiments have been shown and described, variousmodifications and substitutions may be made thereto without departingfrom the spirit and scope of the invention. Those skilled in the artwill readily see other embodiments within the scope of the invention.Accordingly it is to be understood that the method for forming firecombustion modified batts of the present invention has been described byway of illustration only and not limitation.

1. A method for forming a fire combustion modified batt comprising:forming a first blend consisting of oxidized polyacrylonitrile fibers,polyester carrier fibers and polyester binder fibers in which saidpolyester carrier fibers and said oxidized polyacrylonitrile fibers havea combined volume of between 60 percent and 90 percent of said blend,said polyester binder fibers having a low melting temperature relativeto said polyester carrier fibers and said polyester carrier fibershaving a high melting temperature relative to said polyester binderfibers; forming said first blend of fibers into a first web ofindeterminate length; forming a second blend consisting of polyestercarrier fibers and polyester binder fibers, said polyester binder fibershaving a low melting temperature relative to said polyester carrierfibers and said polyester carrier fibers having a high meltingtemperature relative to said polyester binder fibers; forming saidsecond blend of fibers into a second web of indeterminate length;disposing a surface of said first web with a surface of said second webto form a batt; compressing said batt; heating said batt at atemperature at or above the melting temperature of said polyester binderfibers and below the melting temperature of said polyester carrierfibers; and cooling said batt while compressed to (a) fuse saidpolyester binder fibers of said first web of said batt to (i) eachother, (ii) said polyester carrier fibers of said first web of said battand (iii) said oxidized polyacrylonitrile fibers of said first web ofsaid batt; (b) fuse said polyester binder fibers of said second web ofsaid batt to (i) each other and (ii) said polyester carrier fibers ofsaid second web; and (c) fuse the surfaces of said first and said secondwebs together.
 2. The method of claim 1 wherein said polyester binderfibers of said first blend are in an amount of about 5 percent to 40percent by volume of said first blend.
 3. The method of claim 1 whereinsaid polyester binder fibers of said first blend are in an amount ofabout 10 percent to 15 percent by volume of said first blend.
 4. Themethod of claim 1 wherein said polyester binder fibers of said firstblend are in an amount of about 15 percent to 40 percent by volume ofsaid first blend.
 5. The batt produced by the method of claim
 1. 6.Products using the batt of claim 5 wherein said products are selectedfrom the group consisting of bedding, upholstery, furniture, seats,apparel, fire safety gear, air filters, heat shields and insulation forappliances and building, aircraft and vehicle walls.
 7. Mattresses usingthe batt of claim
 5. 8. The method of claim 1 wherein the firecombustion modified batt is a high loft batt having a ratio of weight inounces per square foot to thickness in inches of less than 2 to
 1. 9.The batt produced by the method of claim
 8. 10. Products using the battof claim 9 wherein said products are selected from the group consistingof bedding, upholstery, furniture, seats, apparel, fire safety gear, airfilters, heat shields and insulation for appliances and building,aircraft and vehicle walls.
 11. The method of claim 1 wherein saidcompressing of said batt further comprises: positioning said batt on anair permeable support; and applying a vacuum through said batt from oneside of the batt to the other and through said air permeable supportsufficient to reduce the thickness and increase the density of the battthroughout the thickness of the batt.
 12. The method of claim 1 whereineach of said forming of said first and second blends of fibers intofirst and second webs, respectively, further comprises: moving a websupporting conveyor in the machine direction; and laying each ofsuccessive first and second web layers in the cross direction onto saidmoving conveyor in an over-lapping relation by moving a reciprocatingcross-lapper carrying each of said first and second webs back and forthfrom a first side of the conveyor to an opposing second side.
 13. A firecombustion modified batt comprising: a first web formed of a first blendconsisting of oxidized polyacrylonitrile fibers, polyester carrierfibers and polyester binder fibers in which said polyester carrierfibers and said oxidized polyacrylonitrile fibers are collectively in anamount of about 60 to 90 percent by volume of said blend, said polyesterbinder fibers having a low melting temperature relative to saidpolyester carrier fibers and said polyester carrier fibers having a highmelting temperature relative to said polyester binder fibers; and asecond web formed of a second blend consisting of polyester carrierfibers and polyester binder fibers, said polyester binder fibers havinga low melting temperature relative to said polyester carrier fibers andsaid polyester carrier fibers having a high melting temperature relativeto said polyester binder fibers, a surface of said second web adjacentto a surface of said first web; said polyester binder fibers of saidfirst web heat-fusing (a) said polyester binder fibers of said first webto each other and to said polyester carrier fibers and said oxidizedpolyacrylonitrile fibers of said first web and (b) the adjacent surfacesof said first web and said second web together; said polyester binderfibers of said second web heat-fusing (a) said polyester binder fibersof said first web to each other and to said polyester carrier fibers ofsaid second web and (b) the adjacent surfaces of said first web and saidsecond web together.
 14. The batt of claim 13 wherein said polyesterbinder fibers of said first blend are in an amount of about 5 percent to40 percent by volume of said first blend.
 15. The batt of claim 14wherein the relative percent volume of said oxidized polyacrylonitrilefibers to said polyester carrier fibers in the remaining volume of saidfirst blend is in the range of about 15 percent oxidizedpolyacrylonitrile fibers/85 percent polyester carrier fibers to about 85percent oxidized polyacrylonitrile fibers/15 percent polyester carrierfibers.
 16. The batt of claim 14 wherein the relative percent volume ofsaid oxidized polyacrylonitrile fibers to said polyester carrier fibersin the remaining volume of said first blend is about 50 percent oxidizedpolyacrylonitrile fibers to about 50 percent polyester carrier fibers.17. The batt of claim 13 wherein said polyester binder fibers of saidfirst blend are in an amount of about 10 percent to 15 percent by volumeof said first blend.
 18. The batt of claim 13 wherein said polyesterbinder fibers in said first blend are in an amount of about 15 percentto 40 percent by volume of said first blend.
 19. Products using the battof claim 13 wherein said products are selected from the group consistingof bedding, upholstery, furniture, seats, apparel, fire safety gear, airfilter and insulation for appliances and building, aircraft and vehiclewalls.
 20. Mattresses using the batt of claim
 13. 21. The batt of claim13 wherein the batt is a high loft batt having a ratio of weight inounces per square foot to thickness in inches of less than 2 to
 1. 22.The method of claim 2 wherein said polyester binder fibers of saidsecond blend are in an amount between about 10 percent and about 20percent by volume and said polyester carrier fibers of said second blendare in an amount of at least about 80 percent by volume and less thanabout 90 percent by volume.
 23. The method of claim 2 wherein saidpolyester binder fibers of said second blend are in an amount betweenabout 10 percent and by volume and about 15 percent by volume and saidpolyester carrier fibers of said second blend are in an amount of atleast about 85 percent by volume and less than about 90 percent byvolume.
 24. The method of claim 1 wherein said polyester binder fibersof said second blend are in an amount between about 10 percent and about20 percent by volume and said polyester carrier fibers of said secondblend are in an amount of at least about 80 percent by volume and lessthan about 90 percent by volume.
 25. The method of claim 1 wherein saidpolyester binder fibers of said second blend are in an amount betweenabout 10 percent and by volume and about 15 percent by volume and saidpolyester carrier fibers of said second blend are in an amount of atleast about 85 percent by volume and less than about 90 percent byvolume.
 26. The method of claim 3 wherein said polyester carrier fibersof said second blend are in an amount of at least about 80 percent byvolume and less than about 90 percent by volume.
 27. The method of claim3 wherein said polyester carrier fibers of said second blend are in anamount of at least about 85 percent by volume and less than about 90percent by volume.
 28. The method of claim 4 wherein said polyesterbinder fibers of said second blend are in an amount between about 10percent and about 20 percent by volume and said polyester carrier fibersof said second blend are in an amount of at least about 80 percent byvolume and less than about 90 percent by volume.
 29. The method of claim4 wherein said polyester binder fibers of said second blend are in anamount between about 10 percent and by volume and about 15 percent byvolume and said polyester carrier fibers of said second blend are in anamount of at least about 85 percent by volume and less than about 90percent by volume.
 30. The batt of claim 14 wherein said polyesterbinder fibers of said second blend are in an amount between about 10percent and about 20 percent by volume and said polyester carrier fibersof said second blend are in an amount of at least about 80 percent byvolume and less than about 90 percent by volume.
 31. The batt of claim14 wherein said polyester binder fibers of said second blend are in anamount between about 10 percent and by volume and about 15 percent byvolume and said polyester carrier fibers of said second blend are in anamount of at least about 85 percent by volume and less than about 90percent by volume.
 32. The batt of claim 17 wherein said polyestercarrier fibers of said second blend are in an amount of at least about80 percent by volume and less than about 90 percent by volume.
 33. Thebatt of claim 17 wherein said polyester carrier fibers of said secondblend are in an amount of at least about 85 percent by volume and lessthan about 90 percent by volume.
 34. The batt of claim 18 wherein saidpolyester binder fibers of said second blend are in an amount betweenabout 10 percent and about 20 percent by volume and said polyestercarrier fibers of said second blend are in an amount of at least about80 percent by volume and less than about 90 percent by volume.
 35. Thebatt of claim 18 wherein said polyester binder fibers of said secondblend are in an amount between about 10 percent and by volume and about15 percent by volume and said polyester carrier fibers of said secondblend are in an amount of at least about 85 percent by volume and lessthan about 90 percent by volume.
 36. The batt of claim 13, wherein saidbatt is a high loft batt having a density less than about 1.5 pounds percubic foot.